Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1705

ENGINE FUEL 6C-11

Removal

1. Open the fuel cap to relieve the fuel pressure in the tank.

Use compressed air to remove any dirt on the fuel quick

connect fittings prior to disconnecting the fittings.

When disconnecting the fuel pipe, cover the area with a

cloth to prevent fuel from splashing as the fuel pipe may still

have some pressure in it.

2. For removal of the quick connector, hold the quick

connector in one hand, and pull out the connector with the

other hand while pressing the square relieve button of the

connector, as illustrated.

NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.

Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.

Reuse of Quick-Connector

• Replace the port and connector if scratch, dent or crack is

found.

• Remove any dirt build up on the port when installing the

connector. Replace the connector, if there is any forms of

rust, dent, scratch.

• After cleaning the port, insert it straight into the connector

until it clicks. After it clicks, try pulling at 49N (5kgf) it out to

make sure that it is not drawn and is securely locked.

6C-12 ENGINE FUEL

Assembling Advice

By applying engine oil light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface-which may decrease sealing ability).

Test/Inspection After Assembling

1. Reconnect the battery negative cable.

2. Turn the ignition key to the “ON” position and listen for

pump start-up sound. Inspect for leaks, the fuel pressure

will increase as the fuel pump is actuated.

3. Perform leak inspection (step 2) several times.

4. Start the engine and observe the engine idle speed. The

presence of dirt in the fuel system may affect the fuel

injection system.

Fuel Pump Relay

General Description

In order to control the FPAS operation, the FPAS relay is
provided. When the starter switch is turned to "ON" position,
the FPAS relay operates the FPAS for 2 seconds.
When it is turned to "START" position, the Engine Control
Module receives the reference pulse from the Ignition Control
Module and it operates the relay, again causing the FPAS to
feed fuel.

ENGINE FUEL 6C-13

Fuel Tank

Fuel Tank and Associated Parts

Legend

1 Roll Over&Float Valve (If applicable)

2 Hose; Evaporative Fuel (If applicable)

3 Hose; Air Breather

4 Hose; Fuel Filter

5 Fuel Pump and Sender Assembly

6 Fuel Tank Assembly

7 Hose; Fuel Delivery

8 Hose; Fuel Return

(2.2L & 2.0L Models)

(2.4L Model)

6C-14 ENGINE FUEL

Removal

CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section "Driveability and Emission".

1. Disconnect battery ground cable.

2. Loosen fuel filler cap.

3. Support underneath of the fuel tank protector with a lifter.

4. Disconnect evaporative fuel hose at the canister.

5. Disconnect fuel delivery hose and fuel return hose near the

fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.

6. Disconnect air breather hose (3) and fuel filler hose (4) at

the fuel filler neck.

NOTE: Cover fuel hose to prevent any dust entering.

7. Remove the four fuel tank assembly fixing bolts at four

corners of the tank.

8. Let down the tank and disconnect the wiring connectors

and the emission hose at the emission port on the fuel

pump and sending assembly (5).

9. Remove fuel tank assembly along with protectors.

10. Remove roll over&float valve (1) along with the evaporative

fuel hose and pipe (2).

11. Remove fuel pump and sender assembly (5) by removing

the snap ring along with the fuel hoses (7, 8).

12. Remove tank protector by removing the fixing bolts.

Installation

1. Install protectors and tighten the fixing bolts to the

specified torque.

Torque; 68 N

⋅⋅⋅⋅m (6.9 kgf⋅⋅⋅⋅m)

2. Install fuel pump and sender assembly by fitting in the snap

ring.

3. Install roll over&float valve (1).

4. Lift up fuel tank assembly and connect the emission hose

to the emission port and the wiring connectors on the fuel

pump and sending assembly (5).

5. Install fuel tank assembly along with protectors and tighten

the four fixing bolts to the specified torque.

Torque: 68 N

⋅⋅⋅⋅m (6.9 kgf⋅⋅⋅⋅m)

6. Connect fuel filler hose (4) and air breather hose (3), and

clip them firmly.

7. Connect fuel delivery hose (7) and fuel return hose (8), and

clip them firmly.

8. Connect evaporative fuel hose (2).

9. Tighten fuel filler cap.

10. Connect battery ground cable.